Method for producing an extrudate

ABSTRACT

Aspects of the disclosure relate to methods and systems for producing a preferably strand-like extrudate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This Utility Patent Application claims priority under 35 U.S.C. § 371 toInternational Application Serial No. PCT/EP2019/000097 filed Mar. 27,2019, which claims the benefit of German Application No. DE 10 2018 002544.7, filed Mar. 28, 2018, both of which are incorporated herein byreference.

FIELD OF THE DISCLOSURE

The present disclosure relates to a method for producing an extrudateand a process unit.

BACKGROUND

Process units having a pultrusion unit and an extrusion unit are used toproduce a strand-like extrudate. In the pultrusion unit, a matrix, forexample a thermoplastic material, is usually materially bonded withfibres, and the crude extrudate is furthermore deformed in thepultrusion unit along with the matrix and the fibres. In the extrusionunit, the crude extrudate from the pultrusion unit is formed into theextrudate's final form. In the pultrusion unit, the crude extrudate ismoved through a completely closed pultrusion channel, which is boundedby shaping walls. The cross-sectional area available to the crudeextrudate is therefore limited by the cross-sectional area of thepultrusion channel. Material tolerances, for example of the fibres, maymake it necessary for the crude extrudate in the pultrusion channel totemporarily require a larger cross-sectional area. However, since theavailable cross-sectional area for the crude extrudate is limited by thecross-sectional area of the pultrusion channel, this results in a sharprise in the pressure of the crude extrudate in the pultrusion channeland a blockage, because the crude extrudate rests on the shaping wallwith a large pressing force and there is therefore a large amount offriction between the crude extrudate and the shaping walls. This problemoccurs in particular with a crude extrudate having a small diameter. Forthis reason, the pultrusion unit cannot reliably produce extrudateshaving a small diameter.

DE 10 2015 007 317 A1 shows a method for reinforcing an existing basicstructure with a reinforcing structure. The reinforcing structure isproduced using a process unit having a pultrusion unit and an extrusionunit.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure are described in more detail in thefollowing with reference to the attached drawings.

The figures show:

FIG. 1 a simplified longitudinal section of a process unit with apultrusion unit and an extrusion unit for implementing the method,

FIG. 2 a side view of the process unit during the implementation of themethod,

FIG. 3 a cross-section of a basic structure prior to placement of areinforcing structure,

FIG. 4 the cross-section of the basic structure of FIG. 3 afterplacement of the reinforcing structure,

FIG. 5 a perspective view of a pultrusion unit from the state of theart,

FIG. 6 a section A-A of the pultrusion unit of FIG. 6 ,

FIG. 7 a section B-B of the pultrusion unit of FIG. 6 ,

FIG. 8 a section C-C of the pultrusion unit of FIG. 6 ,

FIG. 9 a perspective view of a pultrusion unit according to theinvention in a first embodiment,

FIG. 10 a longitudinal section of the pultrusion unit through apultrusion channel,

FIG. 11 a section A-A of the pultrusion unit of FIG. 9 ,

FIG. 12 a section B-B of the pultrusion unit of FIG. 9 ,

FIG. 13 a section C-C of the pultrusion unit of FIG. 9

FIG. 14 a perspective view of a pultrusion unit according to theinvention in a second embodiment,

FIG. 15 a section A-A of the pultrusion unit of FIG. 14 ,

FIG. 16 a perspective view of a pultrusion unit according to theinvention in a third embodiment,

FIG. 17 a section A-A of the pultrusion unit of FIG. 16 ,

FIG. 18 a section B-B of the pultrusion unit of FIG. 16 ,

FIG. 19 a section C-C of the pultrusion unit of FIG. 16 ,

FIG. 20 a perspective view of a pultrusion unit according to theinvention in a fourth embodiment,

FIG. 21 a cross-section of a pultrusion channel in a first embodiment,

FIG. 22 a cross-section of a pultrusion channel in a second embodiment,

FIG. 23 a cross-section of a pultrusion channel in a third embodiment,

FIG. 24 a cross-section of a pultrusion channel in a fourth embodiment,

FIG. 25 a cross-section of a roller in a first embodiment,

FIG. 26 a cross-section of a roller in a second embodiment,

FIG. 27 a cross-section of a roller in a third embodiment,

FIG. 28 a cross-section of a roller in a fourth embodiment,

FIG. 29 a view of a hardenable mass and of fibres in a first embodimentfor feeding into the pultrusion unit, and

FIG. 30 a view of a hardenable mass and of fibres in a second embodimentfor feeding into the pultrusion unit.

DETAILED DESCRIPTION

The object of the present invention is therefore to provide a method forproducing an extrudate and a process unit, in which extrudates having asmall diameter or a small cross-sectional area can also be reliablyproduced.

This object is achieved with a method for producing an extrudate,preferably strand-like, comprising the steps: introducing a hardenablematrix and fibres or a crude extrudate into a pultrusion unit, deformingthe crude extrudate in the pultrusion unit wherein during the movementof the crude extrudate through a pultrusion channel of the pultrusionunit, an outer side of the crude extrudate rests on at least one shapingwall of the pultrusion unit, discharging the deformed crude extrudatefrom the pultrusion unit, introducing the crude extrudate dischargedfrom the pultrusion unit into an extrusion unit, deforming the crudeextrudate in the extrusion unit and discharging the crude extrudate thathas been reshaped to form the extrudate from an opening of the extrusionunit, wherein in a section through the crude extrudate perpendicular tothe movement direction of the crude extrudate in the pultrusion channel,a first portion of the outer side of the crude extrudate rests on atleast one shaping to wall of the pultrusion unit during the movementthrough the pultrusion unit and a second portion of the outer side ofthe crude extrudate is not in contact with the at least one shaping walland/or, in a section through the crude extrudate perpendicular to themovement direction of the crude extrudate in the pultrusion channel, theouter side of the crude extrudate rests on at least one shaping wall ofthe pultrusion unit during the movement through the pultrusion unit, andthe distance between a first shaping wall and a second shaping wall isvaried perpendicular to the movement direction of the crude extrudate inthe pultrusion channel, so that the cross-sectional area available tothe crude extrudate between the first and second shaping wall in thepultrusion channel is varied. The cross-sectional area of the crudeextrudate in the pultrusion channel is thus varied during the movementof the crude extrudate at an identical section perpendicular to themovement direction of the crude extrudate in the pultrusion channel, sothat a blockage of the crude extrudate, in particular as a result ofmaterial tolerances, can preferably be substantially avoided. Thecross-sectional area available to the crude extrudate is preferablyvaried by at least 5%, 10%, 20% or 30% because of the movement of thefirst and second shaping wall. The crude extrudate is deformed in thepultrusion unit and the fibres are optionally materially bonded with thematrix in the pultrusion unit. The optional execution of the materialbond between the fibres and the matrix in the pultrusion unit depends onthe type of crude extrudate used. In the case of hybrid yarns, forexample, the fibres and the matrix are not yet materially bonded to oneanother when they are introduced into the pultrusion unit, so that amaterial bond between the fibres and the matrix is produced in thepultrusion unit. If the crude extrudate is a composite tape, the fibresand the matrix are already at least partially materially bonded to oneanother before being introduced into the pultrusion unit, so that no, oronly a minimal, material bond between the fibres and the matrix isproduced in the pultrusion unit. Normally, however, even when the crudeextrudate is a composite tape, a material bond between the fibres andthe matrix is produced in the pultrusion unit, because heating andreshaping the crude extrudate in the pultrusion unit results in anadditional and/or modified material bond between the fibres and thematrix.

In a further embodiment, on the second portion of the outer side of thecrude extrudate, the crude extrudate is only in contact with the ambientair or a process gas. A movement of the crude extrudate on the secondportion of the outer side can therefore be carried out to increase thecross-sectional area of the crude extrudate.

In an alternate embodiment, the at least one shaping wall is fixed, inparticular in a movement direction parallel to the movement direction ofthe crude extrudate, so that the crude extrudate carries out a relativemovement to the at least one shaping wall as a result of the movement ofthe crude extrudate through the pultrusion unit.

In an additional embodiment, as a movement wall, the at least oneshaping wall follows the movement of the crude extrudate through thepultrusion unit at least partially, in particular completely, so thatthe relative movement speed between the movement speed of the crudeextrudate and the movement speed of the at least one movement wall issmaller than the movement speed of the crude extrudate through thepultrusion unit, and the movement speed of the crude extrudate and themovement speed of the at least one movement wall are in particularsubstantially identical, whereby substantially preferably means that themovement speed of the crude extrudate and the movement speed of the atleast one movement wall differ by less than 20%, 10%, 5% or 3%.

The at least one wall is suitably configured as a movement wall of atleast one roller and/or at least one die moved by a mechanism. A radialouter side of the at least one roller rests on the crude extrudate, sothat the rotational speed of the radial outer side of the rollercorresponds substantially to the translational speed of the outer sideof the crude extrudate, because the roller is set in a correspondingrotational movement caused by the crude extrudate. The mechanism isdriven by a motor, in particular an electric motor, and the die isplaced onto the outer side of the crude extrudate and then temporarilyfollows the translational movement of the crude extrudate. The die isthen lifted off the crude extrudate, moved back, and then placed on thecrude extrudate again, whereby this process is carried out repeatedly.

In an additional embodiment, the first and/or second shaping wall ispressed onto the outer side of the crude extrudate with a pressingforce, in particular in a pressing force direction perpendicular to themovement direction of the crude extrudate, so that the first and/orsecond shaping wall is moved in a movement direction perpendicular tothe movement direction of the crude extrudate. The pressing force isnecessary for the shaping wall to cause a sufficient deformation of thecrude extrudate.

The first and/or second shaping wall is preferably pressed onto theouter side of the crude extrudate by means of an actuator, in particularan electric motor or a movable piston, and/or an elastic element, inparticular a spring.

In an additional embodiment, the first and/or second shaping wall isformed by a roller and the roller is moved in a movement directionperpendicular to the movement direction of the crude extrudate. Themovement of the roller changes the cross-sectional area of the crudeextrudate.

In an additional embodiment, the pultrusion channel bounded by the atleast one shaping wall is conically tapered in the movement direction ofthe crude extrudate, so that the width of the crude extrudate decreasesand the thickness of the crude extrudate increases during thedeformation of the crude extrudate in the pultrusion unit.

In an additional embodiment, the fibres are materially bonded with thehardenable matrix in the pultrusion unit, in particular in thepultrusion channel. It depends on the type of crude extrudate usedwhether or not the fibres are materially bonded to the matrix in thepultrusion unit.

In an additional embodiment, the fibres and preferably the hardenablematrix are stressed with a tensile force during the movement of thecrude extrudate through the pultrusion channel of the pultrusion unit.

In a further embodiment, the at least one wall comprises a concaveand/or convex surface as a movement wall, and the concave and/or convexsurface of the movement wall rests on the crude extrudate, so that acomplementary geometry is worked into the outer side of the crudeextrudate.

In an additional embodiment, an existing basic structure is reinforcedwith at least one reinforcing structure to form a supporting structurewith the steps: producing the at least one reinforcing structure,connecting the at least one reinforcing structure to the basicstructure, so that the at least one reinforcing structure is connectedto the basic structure in a connecting position and the basic structuretogether with the at least one reinforcing structure forms thesupporting structure, wherein the at least one reinforcing structure, inparticular all the reinforcing structures, is/are made of a compositematerial with fibres and a matrix by means of pultrusion and/orextrusion and a pultrusion unit and/or an extrusion unit and/or aprocess unit is moved in the space, so that, after the pultrusion and/orextrusion, the at least one reinforcing structure, in particular all thereinforcing structures is/are respectively pultruded and/or extrudedonto the basic structure at the required connecting position and thereinforcing structure is produced as an extrudate using a methoddescribed in this patent application.

The process unit according to the invention, comprising: a pultrusionunit with a pultrusion channel and the pultrusion channel is bounded byat least one shaping wall, an extrusion unit with an extrusion channeland an opening for discharging the extrudate from the extrusion channel,a conveying device for conveying a crude extrudate from the pultrusionunit into the extrusion unit, whereby the pultrusion channel ispartially open.

In a further embodiment, the pultrusion channel is at least partiallysubstantially U-shaped or V-shaped in cross-section.

In an additional embodiment, the method is carried out with a processunit described in this patent application.

The process unit described in this patent application is preferably aprocess unit for carrying out the method described in this patentapplication.

In a further embodiment, the crude extrudate is moved in the extrusionunit through an extrusion channel.

The second portion of the outer side of the crude extrudate preferablycomprises at least 10%, 20% or 30% of the total outer side of the crudeextrudate, in particular in a section perpendicular to the movementdirection of the crude extrudate in the pultrusion channel.

In a further embodiment, a force, in particular a tensile force, isapplied to the crude extrudate with tensioning devices, in particulartensioning rollers, in particular at the beginning and end of thepultrusion unit, so that the crude extrudate, in particular the fibresin the pultrusion channel, have a tensile force in the pultrusion unit.

In a further embodiment, the crude extrudate is deflected by at leastone deflecting device, in particular at least one deflecting roller,before being introduced into the pultrusion channel and/or after beingdischarged from the pultrusion channel, so that, during introduction,the crude extrudate is preferably oriented at an angle α₁ and/or, duringdischarge, at an angle α₂ to a plane perpendicular to the movementdirection of the crude extrudate in the pultrusion channel. The angle α₁and the angle α₂ are preferably between 0° and 90°, in particularbetween 20° and 80°.

The at least one tensioning device suitably also forms at least onedeflecting device.

In a further embodiment, after pultrusion and/or extrusion and placementon the basic structure, the pultruded and/or extruded at least onereinforcing structure, in particular all the reinforcing structures,does/do not carry out a movement relative to the basic structure and/orthe matrix of the pultruded and/or extruded reinforcing structure, inparticular all the reinforcing structures, is/are hardened at therequired connecting position on the basic structure and/or pultrusionand extrusion is carried out simultaneously and/or continuously.

In a further embodiment, pultrusion is carried out as a first step forthe production of the extrudate and extrusion is carried out as a secondstep, so that the pultruded crude extrudate partially produced in thefirst step is post-processed in the second step with extrusion.

The extrudate, in particular the reinforcing structure, preferably allthe reinforcing structures, is/are suitably produced, in particularcontinuously, by moving the pultrusion unit and/or extrusion unit and/orprocess unit, in particular continuously, in the space in a movementpath at and/or in the region of the required connecting position at a orno distance from the basic structure. The distance is in the rangebetween 0 mm and a few mm or cm. The pultrusion unit and/or extrusionunit and/or process unit is moved substantially at the requiredconnecting position because, after the at least one reinforcingstructure is discharged from the process unit, the reinforcing structureis still at a small or no distance from the basic structure.

In a further embodiment, the basic structure of the extrusion unit isplastically and preferably elastically deformed by the extrusion unitduring the movement of the extrusion unit in the space, so that at leastone recess is formed in the basic structure as a result of the plasticdeformation of the basic structure and the at least one reinforcingstructure is placed into the at least one recess at the requiredconnecting position.

The pultrusion unit and/or extrusion unit and/or process unit issuitably moved with a robot and/or, after pultrusion and/or extrusion ofa respective extrudate, the extrudate with the fibres and the matrix iscut with a cutting unit.

In an additional embodiment, the crude extrudate and/or the extrudateare conveyed continuously first through the pultrusion unit and thenthrough the extrusion unit.

Hybrid yarns or composite tapes with fibres and matrix are suitablyconveyed to the pultrusion unit or the fibres and the matrix areconveyed separately to the pultrusion unit.

In an additional embodiment, the fibres are materially bonded to oneanother in the pultrusion unit during pultrusion by means of the matrix,in particular by heating and/or hardening the matrix, and/or coolingand/or hardening the matrix during conveyance from the pultrusion unitto the extrusion unit, so that the fibres are materially bonded to oneanother, and/or the crude extrudate is conveyed by means of a conveyingdevice, for example two conveying wheels, in particular by the conveyingdevice acting on the crude extrudate while conveying the crude extrudatefrom the pultrusion unit to the extrusion unit, and/or the fibres andthe matrix are first deformed by means of pultrusion and preferablymaterially bonded to one another, in particular by heating and/orhardening the matrix, and then the cross-sectional shape of theextrudate is at least partially formed during extrusion in the extrusionunit.

In a further embodiment, the crude extrudate is understood to be anarrangement and/or mixture of matrix and fibres, regardless of whetherthe fibres are materially bonded with the matrix or not.

The extrudate suitably has a maximum diameter of less than 10 mm, 5 mm,3 mm, 1 mm or 0.7 mm. The extrudate has a cross-sectional shape as arectangle, square, or ellipse, for example, with a maximum diameter ofless than 10 mm, 5 mm, 3 mm, 1 mm, or 0.7 mm.

In a further embodiment, the crude extrudate is heated in the pultrusionunit, in particular with a heating device.

In an additional embodiment, the crude extrudate and/or extrudate isdeformed in the extrusion unit.

Suitably, the crude extrudate is initially heated in the pultrusionunit, the crude extrudate cools when it is conveyed from the pultrusionunit to the extrusion unit, and the crude extrudate is then heated againin the extrusion unit.

The crude extrudate is suitably actively cooled in the pultrusion unitwith a, for example first, cooling device.

In a further embodiment, the extrudate is actively cooled after beingconveyed through the extrusion unit with a, for example, second, coolingdevice, for example a blower.

In a further embodiment, the extrudate is produced as a matrix with aplastic, preferably a thermoplastic and/or thermosetting material and/ora plastic as a reactive hot melt or reactive hot melt adhesive orreactive hot melt polymer. Plastics as a reactive hot melt or reactivehot melt adhesive or reactive hot melt polymer are plastics that, forexample, initially have thermoplastic properties and/or are athermoplastic material and, after at least one change parameter, forexample warming or heating and/or exposure to moisture and/orirradiation with UV light and/or removal of oxygen, via a chemicalmodification, in particular at least one chemical reaction, havethermosetting properties and/or are a thermosetting material. If thechange parameter is warming or heating, warming and/or heating can beused as a change parameter in the pultrusion unit and/or extrusion unit.Thermosetting materials are 100% solid even when warmed or heated, i.e.,hardening is not reversible by heating. Warming and/or heating in thepultrusion unit and/or extrusion unit is carried out at temperaturesbetween 60° C. and 200° C., for example. For a reactive hot melt, forexample based on polymers, the chemical modification is carried out viaa connection between existing macromolecular chains (so-calledcross-links). Reactive hot melts are structured on the basis of EVA(ethylene-vinyl acetate) and polyester, for example, or on the basis ofPA (polyamide) or on the basis of polymers or on the basis of PUR.Reactive hot melts can partially also contain substances that are notplastics or adhesives. In this respect, adhesives are also regarded asplastics. The essential property of the reactive hot melt or reactivehot melt adhesive or reactive hot melt polymer is therefore that, afterhardening as a result of the action of the at least one changeparameter, a heating of the at least one reinforcing structure does notcause the reactive hot melt or the matrix made of the reactive hot meltto melt, so that, despite heating to temperatures normal for theapplication, for example temperatures up to 200° C. or 300° C., theload-bearing capacity and/or rigidity of the extrudate is stillguaranteed.

In an additional embodiment, the extrudate is produced with fibres inthe form of glass fibres, carbon fibres and/or aramid fibres.

In a further embodiment, prior to placing the at least one reinforcingstructure on the surface of the basic structure, the material of thebasic structure is removed locally on the surface of the basic structurein the region of a later contact surface between the at least onereinforcing structure and the basic structure.

The basic structure is preferably removed by machining, in particularwith a tool, preferably a milling tool, and the tool is moved along thesurface of the basic structure by a robot.

In an additional embodiment, a preferably elongated recess is workedinto the basic structure as a result of the removal and/or deformation,in particular plastic deformation, of the material of the basicstructure, and the at least one reinforcing structure is then placedinto the recess, so that a form-locking connection between the at leastone reinforcing structure and the basic structure is formed at therecess, in particular after cooling and hardening of the matrix.

In an alternate embodiment, prior to placing the at least onereinforcing structure on the surface of the basic structure, the surfaceof the basic structure is locally heated in the region of a latercontact surface between the at least one reinforcing structure and thebasic structure with a basic structure heating device, in particular alaser or an infrared radiator or a fan heater.

In a further embodiment, the basic structure heating device is movedalong the surface of the basic structure by a robot and/or, as a resultof the heating of the surface of the basic structure, the properties ofthe material of the basic structure are changed locally in the region ofa later contact surface between the at least one reinforcing structureand the basic structure, in particular with respect to being viscousand/or sticky and/or liquid, so that a material bond is to formedbetween the matrix of the at least one reinforcing structure and thematerial of the basic structure, in particular after cooling.

In an additional embodiment, prior to placing the at least onereinforcing structure on the surface of the basic structure, asubstance, in particular an adhesive and/or an adhesion promoter, isapplied locally in the region of a later contact surface between the atleast one reinforcing structure and the basic structure using a supplydevice to improve the connection between the at least one reinforcingstructure and the basic structure.

The supply device is preferably moved along the surface of the basicstructure by a robot.

In one embodiment, the basic structure is produced or provided first,and the at least one reinforcing structure is produced afterwards.

The basic structure is suitably produced using a different method thanthe at least one reinforcing structure.

The basic structure is suitably made of metal, in particular steeland/or aluminium, and/or plastic, in particular fibre-reinforced plasticor styrofoam (generically known as closed-cell extruded polystyrenefoam) or plastic foam or plastic, and/or in sandwich construction of twodifferent materials.

In one embodiment, the basic structure is configured as a planarcomponent, a plate, a disc, a partial spherical shell, a dome, a partialrotational ellipsoid, a well, or a cup.

The invention further includes a computer program with program codemeans stored on a computer-readable data carrier for carrying out amethod described in this patent application when the computer program isexecuted on a computer or a corresponding processing unit.

A further component of the invention is a computer program product withprogram code means stored on a computer-readable data carrier forcarrying out a method described in this patent application when thecomputer program is executed on a computer or a corresponding processingunit.

FIGS. 1 and 2 show a process unit 5 according to the invention forproducing a reinforcing structure 1 as an extrudate 40. The process unit5 comprises a pultrusion unit 6 and an extrusion unit 7. A pultrusionchannel 9 is configured in the pultrusion unit 6 and, in a directionfrom right to left as a movement direction 54 of a crude extrudate 41 asshown in FIG. 1 , the pultrusion channel 9 is initially configured inone section to be conically tapered with a decreasing width 42 and thenwith a constant width 42. The pultrusion channel 9 is bounded by shapingwalls 46. A first heating device 8 and then a first cooling device 10are arranged on the pultrusion channel 9 in a direction as shown in FIG.1 from right to left as the movement direction 42, and also in aconveying direction of hybrid yarns 21 or the extrudate 40 to beproduced. The heating device 8 and the cooling device 10 also form theshaping walls 46. A cooling channel 11 is configured on the firstcooling device 10, through which a cooling fluid is moved to cool thecrude extrudate 41. Under the plane of the drawing of FIG. 1 , thepultrusion channel 9 is bounded by a further, not depicted, shaping wall46. There is no shaping wall 46 above the plane of the drawing of FIG. 1. A first portion 52 of the outer side 51 of the crude extrudate 41 orthe matrix 44 with the fibres 45 rests on the shaping walls 46 of thepultrusion unit 6. A different, second portion 53 of the outer side 51of the crude extrudate 41 not shown in FIG. 1 is not in contact with ashaping wall 46 and is only in contact with the ambient air. Thepultrusion channel 9 is thus partially open above the plane of thedrawing of FIG. 1 . An arrangement and/or mixture of matrix 44 andfibres 45 is already considered to be a crude extrudate 41 before it isintroduced into the pultrusion channel 9. The matrix 44 and the fibres45 are thus also referred to as the crude extrudate 41 throughout thepultrusion channel 9 and before the pultrusion channel 9, without orwith a material bond between the fibres 45 and the matrix 44.

The extrusion unit 7 comprises an extrusion channel 15, and theextrusion channel 15 comprises a first conically tapered section and asecond section with a constant diameter. A second heating device 16 isprovided on the second section of the extrusion channel 15 with theconstant diameter. The first and second heating device 8, 16 ispreferably configured as an electrical resistance heater. In theconveying direction of the extrudate 40 through the extrusion channel15, the conically tapered section of the extrusion channel 15 isfollowed by the section of the extrusion channel 15 with the constantdiameter. A conveying device 12 is provided between the pultrusion unit6 and the extrusion unit 7. The conveying device 12 comprises a firstconveying wheel 13 and a second conveying wheel 14, which are driven bya not depicted electric motor. The crude extrudate 41 is positionedbetween the two conveying wheels 13, 14, so that the crude extrudate 41is pulled out of the pultrusion unit 6 with the conveying device 12 andpushed into the extrusion unit 7 with the conveying device 12.

The pultrusion unit 6 and the extrusion unit 7 are connected to oneanother with a connecting part 20, for example a housing shown onlypartially in FIG. 1 . A feed part 23 having three guide bores 24 isattached to the connecting part 20 as well. A hybrid yarn 21 isrespectively rolled up on three rollers 22 as storage rollers 22. Thehybrid yarn 21 consists of a fibre 45 as a glass fibre 45 and alsocomprises the matrix 44 made of a thermoplastic material. The matrix 44as the thermoplastic material is provided in the hybrid yarn 21 as afibrous matrix 44 or as a matrix fibre 44. The hybrid yarn 21 isflexible and can therefore be unwound from the roller 22. A secondcooling unit 17 is attached to the extrusion unit 7 as well. The secondcooling unit 17 comprises a blower 18 and a cooling pipe 19. With theaid of the blower 18, ambient air is guided through the cooling pipe 19and directed to the region of the reinforcing structure 1 immediatelyafter leaving the extrusion unit 7. A cutting unit 25 is used to cut theextrudate 40 extruded at the extrusion unit 7 if necessary, and is thusto be able to produce an end of the extrudate 40.

During the production of the reinforcing structure 1 as the extrudate 40of the composite material 29 with the fibres 45 and the matrix 44, theextrudate 40 is conveyed first through the pultrusion unit 6 and thenthrough the extrusion unit 7 by means of the conveying device 12 asshown in FIG. 1 . However, due to the length of the rods 2 and thedistance between the pultrusion unit 6 and the extrusion unit 7, the twoprocesses take place at the same time. The hybrid yarn 21 is thusunwound from the three rollers 22 during the conveying of the crudeextrudate 41, and fed into the conically tapered section of thepultrusion channel 9. The three hybrid yarns 21 are heated with thefirst heating device 8 at the conically tapered section of thepultrusion channel 9 with a decreasing width 42 in the movementdirection 54, so that the thermoplastic material of the matrix 44 on thehybrid yarns 21 melts and the glass fibres 45 in the three hybrid yarns21 are thus materially bonded to one another by means of the matrix 44of the thermoplastic material as a process step of pultrusion. Inaddition, as a further process step, a reshaping or deformation of thematrix 44 and the fibres 45 or the crude extrudate 41 is carried out inthe pultrusion unit 6, so that the crude extrudate 41 discharged fromthe pultrusion unit 6 has the proper shape for the extrusion unit 7.

The crude extrudate 41 is then conveyed or moved to the section of thepultrusion channel 9 with the first cooling device 10, so that the crudeextrudate 41 is cooled and thus partially hardened. After the crudeextrudate 41 is discharged, the crude extrudate 41 is conveyed or fedinto the extrusion unit 7 by the conveying device 12. Because the crudeextrudate 41 is cooled in the first cooling device 10, the crudeextrudate 41 can be conveyed by the conveying device 12. In theextrusion unit 7, the crude extrudate 41 as a composite material 29 withthe fibres 45 and the matrix 44 is heated again at the section of theextrusion channel 15 with the constant diameter by the second heatingdevice 16 to such an extent that, at the end region in the conveyingdirection of the extrusion channel 15, the final shaping of thecross-sectional shape of the reinforcing structure 1 to be produced isformed at an opening 60 as the end of the extrusion channel 15. Theopening 60 has a circular cross-sectional shape, so that reinforcingstructures 1 are produced as extrudates 40 with a circular cross-sectionby means of the process unit 5. After the extrudate 40 is dischargedfrom the extrusion channel 15 of the extrusion unit 7, the blower 18moves ambient air as cooling air through the cooling pipe 19 to the rod2 as the extrudate 40, so that faster cooling of the reinforcingstructures 1 can be achieved.

The reinforcing structures 1 as extrudates 40 produced with the methodare configured as straight or curved rods 2. The rods 2 are produced bythe process unit 5 at the required connecting position on a basicstructure 4, so that the process unit 5 is moved on a movement path 26as a straight line 27 or a curved line 27 by means of movement arms 28of a robot shown in FIG. 2 in a highly simplified form. The movementpath 26 as a straight line 27 or a curved line 27 substantiallycorresponds to the longitudinal axis of the reinforcing structure 1produced by the process unit 5. After the production of the rods 2 andthe placement of the rods 2 or the reinforcing structures 1 on thesurface of the basic structure 4, no relative movement or movement ofthe produced rods 2 relative to other already produced or yet to beproduced rods 2 or to the basic structure 2 is necessary, because therods 2 are already produced with the process unit 5 at the requiredconnecting position on the basic structure 4. FIG. 2 does not show therollers 22 and the hybrid yarns 21. The reinforcing structure 1 consistsof rods 2 of the composite material 29, namely with fibres 45 as glassfibres 45 and the matrix 44 as the thermoplastic material.

In a further, not depicted embodiment of the process unit 5, the fibres,for example glass, aramid, or carbon fibres, are wound onto the rollers22 and the matrix as the thermoplastic material is stored separately ina heated state in a container with a container heater and conveyed tothe pultrusion unit 6 by means of a not depicted matrix conveyingdevice. The pultrusion unit 6 and the extrusion unit 7 can also beconfigured as only one component, for example by carrying out theextrusion, i.e., the final shaping of an outer side 33 of the rod 2 asthe extrudate 40, immediately after pultrusion, without the conveyingdevice 12 being disposed between the extrusion unit 7 and the pultrusionunit 6.

In a further, not depicted embodiment, a thermosetting material or aplastic as a reactive hot melt or reactive hot melt adhesive or reactivehot melt polymer is used instead of a thermoplastic material as thematrix. The thermosetting material is stored separately in a containerand fed to the extrusion unit 7 and/or the pultrusion unit 6 using amatrix conveying device. The hardening of the thermosetting material iscarried out by means of irradiation or the addition of chemicaladditives. The hardening of the plastic as a reactive hot melt orreactive hot melt adhesive or reactive hot melt polymer is in particularcarried out via heating as a change parameter during the processing ofthe matrix in the pultrusion unit 6 and/or in the extrusion unit 7.Deviating from this, the hardening of the plastic as a reactive hot meltcan also be carried out with the aid of moisture and/or UV light and/orthe removal of oxygen. In the case of hardening by UV light, the atleast one reinforcing structure 1 is irradiated with UV light by meansof a UV light source (not depicted) after the at least one reinforcingstructure 1 has been placed on the basic structure 4.

In a further, not depicted embodiment of the process unit 5, thecomposite tapes are wrapped onto the rollers 22. Due to apreconsolidation of the matrix 44, the fibres 45 of composite tapes arealready at least partially, and in particular completely, materiallybonded to the matrix 44, so that generally only a slight material bondbetween the fibres 45 and the matrix 44 is created in the pultrusionunit 6.

Preprocessing devices 34, 36, 38 as a tool 34, as a milling tool 35, abasic structure heating device 36, for example a laser 37, or aninfrared radiator 38, and a supply device 39 for adhesive 31 areattached to the process unit 5 (shown only in FIG. 2 ). The tool 34, thebasic structure heating device 36, and the supply device 39 can be movedrelative to the process unit 5 with mechanical devices, so that thepreprocessing devices 34, 36, 38 can be disposed in the requiredposition on different movement paths 26 with different surfaces of basicstructures 4. Prior to placing the reinforcing structure 1 produced onthe process unit 5 on the surface of the basic structure 4, an elongatedrecess 32 (FIG. 3 ) having any desired cross-sectional shape, dependingon the geometry of the milling tool 35, is milled into the basicstructure 4 with the milling tool 35. The recesses 32 have an undercut,so that, after cooling and hardening of the composite material 29 withthe fibres and the matrix within the recess 32, a form-lockingconnection of the rods 2 as the reinforcing structure 1 on the basicstructure 1, for example plates 30, is formed.

The surface of the basic structure 4 is then heated in the region of therecess 32 with the basic structure heating device 36, so that the matrixof the composite material 29 can bond with the material of the basicstructure 4 and, after cooling and hardening of the composite material29 and the basic structure 4, there is a solid material bond between thebasic structure 4 and the reinforcing structure 1.

Subsequently, adhesive 31 is applied to the surface of the basicstructure 4 in the region of the recess 32 with the supply device 39 inorder to materially bond the reinforcing structure 1 to the basicstructure 4 after the reinforcing structure 1 has been placed on thebasic structure 4 and the adhesive 31 has hardened. In general,depending on the material of the basic structure 4, only the basicstructure heating device 36 or only the supply device 39 is operated.For a basic structure 4 made of metal, for example steel or aluminium,only the supply device 39 and not the basic structure heating device 36is operated. For a basic structure 4 made of thermoplastic material,only the basic structure heating device 36 and not the supply device 39is operated.

FIGS. 5 to 8 show a pultrusion unit 5 known from the state of the art ofa (not depicted) process unit 5 known from the state of the art, wherebynecessary functional components, such as a first heating device or afirst cooling device, are not shown for the sake of simplicity. Thecrude extrudate 41 is moved through a pultrusion channel 9. Thepultrusion channel 9, which is circular in cross-sectional shape andtapers conically in the movement direction 54 of the crude extrudate 41,is bounded by a shaping wall 46 of the pultrusion unit 6. In the sectionin FIGS. 6 to 8 perpendicular to the movement direction 54 of the crudeextrudate 41, the entire outer side 51 of the crude extrudate 41 restson the shaping wall 46, so that there is a closed pultrusion channel 9.In the case of a small cross-sectional shape of the pultrusion channel9, in particular in the end region, for diameters less than 1 mm, thematerial tolerances of the fibres 45 and the matrix 44 can lead toclogging and blockages, so that the pultrusion unit 6 is no longerfunctional, i.e., the process unit 5 can no longer produce extrudate 40.The cross-sectional area available to the crude extrudate 41 is limitedby the closed pultrusion channel 9 and local increases in thecross-sectional area of the crude extrudate 41 to prevent blockages arestructurally impossible. Due to the closed form of the pultrusionchannel 9, the pressure of the crude extrudate 41 is high and increasessharply due to the decreasing cross-sectional area as the crudeextrudate 41 moves through the pultrusion channel 9.

FIGS. 9 to 13 show a first embodiment of the pultrusion unit 6 of theprocess unit 5 according to the invention. For the sake of simplicity,necessary functional components, such as a first heating device or afirst cooling device, are not shown. A (not depicted) heating device isconfigured on the shaping walls 46, which allows the crude extrudate 41to be heated by the heated shaping walls 46 so that the matrix 44 can bedeformed and the fibres 45 can optionally bond materially with thematrix 44 during pultrusion in the pultrusion unit 6. The process stepsof deforming the crude extrudate 41 and preferably materially bondingthe fibres 45 with the matrix 44 are thus carried out in the pultrusionunit 6. The substantially U-shaped pultrusion channel 9 is partiallyopen, so that, on the outer side 51, the crude extrudate 41 rests on afirst portion 52 of the outer side 51 with fixed shaping walls 46 and,on a second portion 53 of the outer side 51, the outer side 51 has nocontact with the shaping wall 46, i.e., there is contact only with theambient air. Because of the open second portion 52 of the outer side 51,the pressure of the crude extrudate 41 is very small and substantiallyconstant as the crude extrudate 41 moves through the pultrusion channel6.

In the section in FIGS. 11 to 13 perpendicular to the movement direction54 of the crude extrudate 41, the three shaping walls 46, which arefixed, in particular in a movement direction 54 of the crude extrudate41, are perpendicular to one another and two shaping walls 46 arealigned parallel to one another in the section. The crude extrudate 41in the pultrusion channel 9 has a width 42 and a thickness 43. Theshaping walls 46, which are aligned parallel to one another in thesection, also taper conically toward one another in the movementdirection 54 of the crude extrudate 41 (FIG. 9 ), so that the width 42decreases and the thickness 43 increases as the crude extrudate 41 movesthrough the pultrusion channel 9 (FIGS. 11 to 13 ). Even with a distancesmaller than the width 42, for example 0.5 mm, in the end region of thepultrusion channel 9 between the two shaping walls aligned parallel toone another in the section, material tolerances 46 in the fibres 45 andthe matrix 44 do not lead to a blockage of the crude extrudate 41because, in view of material tolerances, the deformable crude extrudate41 can move into the region of the pultrusion channel 9 without crudeextrudate 41; i.e., the thickness 43 increases locally and the blockageis consequently avoided. The maximum cross-sectional area of the crudeextrudate 41 can thus be increased substantially, because the free spacein the pultrusion channel 9 is dimensioned such that the increases inthe cross-sectional area of the crude extrudate 41 that are required inthe event of material tolerances are available to prevent blockages. Thethickness 43 of the crude extrudate 41 is the extension of the crudeextrudate 41 in the direction of the opening of the pultrusion channel 9and/or in the direction perpendicular to the width 42 of the crudeextrudate 41. The width 42 of the crude extrudate 41 is the extension ofthe crude extrudate 41 in the direction perpendicular to the thicknessand/or the extension of the crude extrudate 41 between the two shapingwalls 46.

Because the three shaping walls 4 are fixed, the relative movement speedbetween the crude extrudate 41 and the three shaping walls 46corresponds to the movement speed of the crude extrudate 41. Notdepicted tensioning devices, in particular tensioning rollers, whichexert a tensile force F1 and F2 on the crude extrudate 41, are providedat the beginning and end of the pultrusion unit 6, so that the crudeextrudate 41 in the pultrusion unit 6 has a tensile force. The tensileforce F1 is smaller than the tensile force F2, so that the crudeextrudate 41 is moved through the pultrusion channel 9 under a tensileforce in the crude extrudate 41, in particular a tensile force in thefibres 45 of the crude extrudate 41. The tensioning devices, inparticular tensioning rollers, additionally function as deflectingdevices, in particular deflecting rollers, so that the crude extrudate41 is deflected before being introduced into the pultrusion channel 9and after being discharged from the pultrusion channel 9 and the crudeextrudate 41 is oriented at an angle α₁ before being introduced and atan angle α₂ after being discharged. The angles α₁ and α₂ are less than90°, so that the crude extrudate 41 is not aligned parallel to themovement direction 54 in the pultrusion channel 9 when being introducedand discharged, but rather at an acute angle. For this purpose, thedeflecting devices exert a lateral force FQ on the crude extrudate 41when it is being introduced and discharged. The lateral force FQ is afunction of the angles α₁ and α₂.

FIGS. 14 and 15 show a second embodiment of the pultrusion unit 6 of theprocess unit 5 according to the invention. In the following, only thedifferences to the embodiment in FIGS. 9 to 13 are described. A roller55 is disposed at an end region of the partially open pultrusion channel9. The roller 55 is mounted so as to be rotatable about an axis ofrotation 62 and a radial outer side 63 as a surface of the roller 55rests on the second portion 53 of the outer side 51 of the crudeextrudate 41 and deforms the second portion 53. Therefore, at this endregion of the pultrusion channel 9 with the roller 55, there is a closedpultrusion channel 9. The axis (not depicted) of the roller 55 ispressed by an elastic element 56 as a spring 57 against the secondportion 53 of the outer side 51 with a pressing force, so that theradial outer side 63 rests with a pressing force on the second portion53 of the outer side 51 of the crude extrudate 41. The axis of theroller 55 is furthermore mounted in a direction perpendicular to themovement direction 54, so that the radial outer side 63 of the roller 55as the first shaping wall 47, which rests on the crude extrudate 41,changes the distance 50 to the opposite shaping wall 46 as the secondshaping wall 48. The cross-sectional area is thereby changed as well.The roller 55 thus also forms a movement wall 49 as a moving shapingwall 46. The axial extension of the roller 55 is slightly smaller thanthe width 42 of the crude extrudate 41 or the distance between theshaping walls 46 aligned parallel in the section, so that the roller 55is partially disposed in the pultrusion channel 9. Changes in thecross-sectional area of the crude extrudate 9, in particular as a resultof material tolerances, can thus be absorbed by the movement as atranslational movement of the roller 55 without the risk of blockages ofthe crude extrudate 9. Due to the rotational movement of the roller 55about the axis of rotation, the first shaping wall 47 formed by theradial outer side 63 of the roller 55 follows the translational movementof the crude extrudate 41, so that there is substantially no relativemovement speed between the rotating radial outer side 63 of the roller55 and the second portion 53 of the outer side 51 of the crude extrudate41.

FIGS. 16 and 19 show a third embodiment of the pultrusion unit 6 of theprocess unit 5 according to the invention. In the following, only thedifferences to the embodiment in FIGS. 9 to 13 are described. Thepultrusion channel 9 is formed by the radial outer sides 63 of threerollers 55. The radial outer sides 63 thus have a concave, substantiallyU-shaped surface 59. The width 42 of the pultrusion channel 9 and thusof the crude extrudate 41 decreases from the first roller 55 shown inFIG. 17 to the third roller 55 shown in FIG. 19 , and the roller 55shown in FIG. 18 has an intermediate width 42 between the first andthird roller 55. Due to the rotational movement of the rollers 55, thereis substantially no relative movement speed between the radial outerside 63 of the rollers 55 and the crude extrudate 41. The crudeextrudate 41 heated with a not depicted heating device is deformed atthe three sections of the pultrusion channel 9 of the three rollers 55.The rollers 55 are also provided with a further optional heating device,in particular an electrical resistance heating device, so that thematrix 44 can be heated for the optional material bond with the fibres45.

FIG. 20 shows a fourth embodiment of the pultrusion unit 6 of theprocess unit 5 according to the invention. In the following, only thedifferences to the embodiment in FIGS. 16 to 19 are described. The threesections of the pultrusion channel 9 are bounded by two rollers 55. Theradial outer sides 63 of the two rollers 55 in a respective section areidentical and correspond to those in the embodiment shown in FIGS. 16 to19 . The concave, substantially U-shaped radial outer sides 63 usuallyrespectively bound half of the pultrusion channel 9 in a respectivesection. The radial outer sides 63 of the two rollers 55 in a respectivesection usually lie on top of one another outside the substantiallyU-shaped recesses. The axis of a roller 55 in a respective sectioncannot be moved in the space perpendicular to the movement direction 54of the crude extrudate 41, so that this roller 55 forms a second shapingwall 48. The other roller 55 as the first shaping wall 47 in arespective section is pressed with an elastic element 56 as a spring 57against the roller 55 that forms the second shaping wall 48. The axis ofthe other roller 55 as the first shaping wall 47 is mounted to bemovable in a movement direction perpendicular to the movement direction54 of the crude extrudate 41, so that the roller 55 as the first shapingwall 47 also forms a movement wall 49 because the distance between thetwo rollers 55 in a respective section can be changed. When the distancebetween the two rollers 55 of a section is increased, thecross-sectional area of the crude extrudate 41 is increased to avoidblockages of the crude extrudate 41 in view of material tolerances.

FIGS. 21 to 24 show different cross-sectional shapes for fixed shapingwalls 46 for the substantially U- or V-shaped pultrusion channel 9. FIG.22 shows a covering wall 61 and the crude extrudate 41 with dashedlines. The crude extrudate 41 is at a large distance from the coveringwall 61, so that even in the event of large material tolerances and alarge increase in the cross-sectional area of the crude extrudate 41,the crude extrudate 41 has no contact with the covering wall 61 andthere is also a partially open pultrusion channel 9 in FIG. 22 . Thecovering wall 61 allows the crude extrudate 41 and/or the fibres 45 withthe matrix 44 to be placed more easily into the pultrusion channel 9during the initial setup, and the partially open pultrusion channel 9 isprotected from contamination and mechanical influences from outside.

FIG. 25 and FIG. 26 show examples of the concave surface 59 of theradial outer side 63 of the rollers 55. The recess for the pultrusionchannel 9 is substantially U-shaped in FIG. 25 and substantiallyV-shaped in FIG. 26 .

FIG. 27 and FIG. 28 show examples of the convex surface 58 of the radialouter side 63 of the rollers 55. In FIG. 27 , the convex surface 58 issubstantially U-shaped and in FIG. 28 it is substantially V-shaped. Therollers 55 shown in FIGS. 27 and 28 allow a deformation of the secondportion 53 of the outer side 51 of the crude extrudate 41, for examplein the embodiment shown in FIGS. 14 and 15 .

FIGS. 29 and 30 show two examples for the configuration of the matrix 44and the fibres 45 as the crude extrudate 41 before being introduced intothe pultrusion channel 9. The matrix 44 and the fibres 45 are flexibleand rolled up on a roller 22. FIG. 29 shows a strip with a substantiallyrectangular cross-section, in which the fibres 45 are surrounded by thematrix 44. In FIG. 30 , the matrix 44 is divided into severalstrand-like pieces, between and around which the fibres 45 are disposed.

All in all, significant advantages are associated with the method forproducing an extrudate 40 according to the invention and the processunit 5 according to the invention. The pultrusion of the crude extrudate41 in the partially open pultrusion channel 9 and/or in a pultrusionchannel 9 with a variable cross-sectional area allows the safe andreliable pultrusion of crude extrudates 41, even with a small diameterin the 0.5 mm range, without the risk of blockages of the crudeextrudate 41 in the pultrusion channel 9. Material tolerances cantemporarily cause an increase in the cross-sectional area of the crudeextrudate 41 and this increase can be realised by moving a secondportion 53 of the outer side 51 outward and/or increasing the distancebetween the first and second shaping wall 47, 48.

The invention claimed is:
 1. A method for producing an extrudate, themethod comprising: introducing a crude extrudate into a pultrusion unit;deforming the crude extrudate in the pultrusion unit wherein, duringmovement of the crude extrudate through a pultrusion channel of thepultrusion unit, an outer side of the crude extrudate rests on at leastone shaping wall of the pultrusion unit; discharging the deformed crudeextrudate from the pultrusion unit; introducing the crude extrudatedischarged from the pultrusion unit into an extrusion unit; anddeforming the crude extrudate in the extrusion unit and discharging thecrude extrudate that has been reshaped to form the extrudate from anopening of the extrusion unit; wherein during movement of the crudeextrudate through the pultrusion channel, in a cross-section through thecrude extrudate perpendicular to a movement direction of the crudeextrudate in the pultrusion channel, a first portion of the outer sideof the crude extrudate rests on at least one shaping wall of thepultrusion channel, and a remaining second portion of the outer side ofthe crude extrudate faces an open side of the pultrusion channel, and ina section through the crude extrudate perpendicular to the movementdirection of the crude extrudate in the pultrusion channel, the outerside of the crude extrudate rests on at least one shaping wall of thepultrusion channel during movement through the pultrusion unit, and adistance between a first shaping wall and a second shaping wall of thepultrusion channel is varied perpendicular to the movement direction ofthe crude extrudate in the pultrusion channel, so that a cross-sectionalarea available to the crude extrudate between the first and secondshaping wall in the pultrusion channel is varied, wherein the crudeextrudate is deflected by at least one roller at an end of thepultrusion unit exerting a force on the crude extrudate in a directionfrom the outer side towards the shaping wall so that during thedischarging, a tensile force is applied to the crude extrudate so thatfibers in the pultrusion channel have a tensile force in the pultrusionunit, and so that during the discharging, the crude extrudate isoriented at an angle between 20° and 80° to a plane perpendicular to themovement direction of the crude extrudate in the pultrusion channel. 2.The method of claim 1, wherein the second portion of the outer side ofthe crude extrudate facing the open side of the pultrusion channel is incontact with ambient air or a process gas.
 3. The method of claim 1,wherein the at least one shaping wall is fixed so that the crudeextrudate carries out a relative movement to the at least one shapingwall as a result of movement of the crude extrudate through thepultrusion unit.
 4. The method of claim 1, wherein as a movement wall,the at least one shaping wall follows the movement of the crudeextrudate through the pultrusion unit at least partially so that arelative movement speed between the movement speed of the crudeextrudate and the movement speed of the at least one movement wall issmaller than the movement speed of the crude extrudate through thepultrusion unit, and the movement speed of the crude extrudate.
 5. Themethod of claim 1, wherein a first or second shaping wall is pressedonto the outer side of the crude extrudate with a pressing force so thatthe first or second shaping wall is moved in a movement directionperpendicular to the movement direction of the crude extrudate.
 6. Themethod of claim 1, wherein a first or second shaping wall is formed by aroller and the roller is moved in a movement direction perpendicular tothe movement direction of the crude extrudate.
 7. The method of claim 1,wherein the pultrusion channel bounded by the at least one shaping wallis conically tapered in the movement direction of the crude extrudate,so that a width of the crude extrudate decreases and a thickness of thecrude extrudate increases during the deformation of the crude extrudatein the pultrusion unit.
 8. The method of claim 1, wherein fibres arematerially bonded with a hardenable matrix in the pultrusion channel. 9.The method of claim 1, wherein an existing basic structure is reinforcedwith at least one reinforcing structure to form a supporting structureby: producing the at least one reinforcing structure, connecting the atleast one reinforcing structure to the basic structure, so that the atleast one reinforcing structure is connected to the basic structure in aconnecting position and the basic structure together with the at leastone reinforcing structure forms the supporting structure, wherein the atleast one reinforcing structure is made of a composite material withfibres and a matrix by pultrusion and a pultrusion unit and/or a processunit is moved, so that, after the pultrusion, the at least onereinforcing structure, in particular all the reinforcing structures arerespectively pultruded onto the basic structure at the connectingposition and the reinforcing structure is produced as an extrudate. 10.The method of claim 1, wherein an existing basic structure is reinforcedwith at least one reinforcing structure to form a supporting structureby: producing the at least one reinforcing structure, connecting the atleast one reinforcing structure to the basic structure, so that the atleast one reinforcing structure is connected to the basic structure in aconnecting position and the basic structure together with the at leastone reinforcing structure forms the supporting structure, wherein the atleast one reinforcing structure is made of a composite material withfibres and a matrix by extrusion and an extrusion unit and a processunit is moved, so that, after the extrusion, the at least onereinforcing structure is respectively extruded onto the basic structureat the connecting position and the reinforcing structure is produced asan extrudate.
 11. The method of claim 1, wherein the deforming the crudeextrudate in the pultrusion unit is carried out in a first step and thedeforming the crude extrudate in the extrusion unit is carried out in asecond step, wherein the crude extrudate discharged from the pultrusionunit is post-processed in the second step.
 12. The method of claim 1,wherein the open side of the pultrusion channel extends for a fulllength of the pultrusion channel.
 13. The method of claim 1, wherein thedistance between the first shaping wall and the second shaping walldecreases over a full length of the pultrusion channel.
 14. The methodof claim 1, the method further including: wherein the extrudate isactively cooled after being conveyed through the extrusion unit.
 15. Themethod of claim 4, wherein the at least one wall is configured as amovement wall of at least one roller or at least one die moved by amechanism.
 16. The method of claim 5, wherein the first or secondshaping wall is pressed onto the outer side of the crude extrudate bymeans of an actuator selected from the group consisting of an electricmotor, a movable piston, and an elastic element.
 17. The method of claim8, wherein during movement of the crude extrudate through the pultrusionchannel of the pultrusion unit, fibres and the hardenable matrix arestressed with a tensile force.
 18. The method of claim 17, wherein theat least one wall comprises a curved surface as a movement wall, and thecurved surface of the movement wall rests on the crude extrudate, sothat a complementary geometry is worked into the outer side of the crudeextrudate.
 19. A method for producing an extrudate, the methodcomprising: introducing a crude extrudate into a pultrusion unit;deforming the crude extrudate in the pultrusion unit wherein, duringmovement of the crude extrudate through a pultrusion channel of thepultrusion unit, an outer side of the crude extrudate rests on at leastone shaping wall of the pultrusion unit; discharging the deformed crudeextrudate from the pultrusion unit; introducing the crude extrudatedischarged from the pultrusion unit into an extrusion unit; anddeforming the crude extrudate in the extrusion unit and discharging thecrude extrudate that has been reshaped to form the extrudate from anopening of the extrusion unit; wherein during movement of the crudeextrudate through the protrusion channel, in a cross-section through thecrude extrudate perpendicular to a movement direction of the crudeextrudate in the pultrusion channel, the outer side of the crudeextrudate rests on at least one shaping wall of the pultrusion channeland a remaining second portion of the outer side of the crude extrudatefaces an open side of the pultrusion channel, and wherein a distancebetween a first shaping wall and a second shaping wall of the at leastone shaping wall is varied perpendicular to the movement direction ofthe crude extrudate in the pultrusion channel, so that a cross-sectionalarea available to the crude extrudate between the first and secondshaping wall in the pultrusion channel is varied; further wherein thecrude extrudate is deflected by at least one roller at an end of thepultrusion unit exerting a force on the crude extrudate in a directionfrom the outer side towards the shaping wall so that during thedischarging, a tensile force is applied to the crude extrudate so thatfibres in the pultrusion channel have a tensile force in the pultrusionunit, and so that during the discharging, the crude extrudate isoriented at an angle between 20° and 80° to a plane perpendicular to themovement direction of the crude extrudate in the pultrusion channel. 20.The method of claim 9, wherein the basic structure is made of materialsselected from the group consisting of metal, aluminium, plastic,fibre-reinforced plastic, closed-cell extruded polystyrene foam, plasticfoam, and plastic.
 21. The method of claim 10, wherein the basicstructure is made of materials selected from the group consisting ofmetal, aluminium, plastic, fibre-reinforced plastic, closed-cellextruded polystyrene foam, plastic foam, and plastic.